Device for facilitating repetitive manufacture of parts having precisionally positioned components with a three-dimensional object printer

ABSTRACT

A printer is configured with positioning members that hold components at predetermined positions to enable a controller operating at least one printhead in a three-dimensional object printer to form structure about the components. The positioning members can then be removed from the printed three-dimensional object to enable continued formation of the three-dimensional object.

TECHNICAL FIELD

This disclosure relates generally to three-dimensionally printedobjects, and more particularly to the manufacture of three-dimensionallyprinted objects having precisely positioned components.

BACKGROUND

Digital three-dimensional object manufacturing, also known as digitaladditive manufacturing, is a process of making a three-dimensional solidobject from a digital model. Three-dimensional object printing is anadditive process in which successive layers of material are formed on asubstrate in different shapes. The layers can be formed by ejectingbinder material, directed energy deposition, extruding material,ejecting material, fusing powder beds, laminating sheets, or exposingliquid photopolymer material to a curing radiation. The substrate onwhich the layers are formed is supported either on a platform that canbe moved three dimensionally by operation of actuators operativelyconnected to the platform, or the material deposition devices areoperatively connected to one or more actuators for controlled movementof the deposition devices to produce the layers that form the object.Three-dimensional object printing is distinguishable from traditionalobject-forming techniques, which mostly rely on the removal of materialfrom a work piece by a subtractive process, such as cutting or drilling.

One shortcoming in the production of three-dimensional objects isprecise positioning of pre-fabricated components within an object.Currently, precise positioning of components in subtractivemanufacturing methods is achieved by precision machining of mounting andlocating features for components within a casting that contains thecomponents. The costs associated with the machining process to formthese features as well as the subsequent inspection to verify thetolerances of the machining are steep. In order to incorporate preciselypositioned components in a three-dimensionally printed objects, aportion of the three-dimensionally printed object needs to be printed,the printed structure cured, the components installed, and the remainderof the object printed. This intermingling of operations and reliance onfreshly printed structures in the object to hold the components andmaintain the precise positioning of the components is difficult toachieve. Thus, a three-dimensional object printer that can form objectswith precisely positioned components would be useful.

SUMMARY

A printer that enables the manufacture of three-dimensionally printedobjects having precisely positioned components includes a support memberconfigured to support a three-dimensional object to be formed by athree-dimensional object printer, at least one positioning membermounted to the support member, the at least one positioning member beingconfigured to hold a component at a predetermined position withreference to the support member, at least one printhead configured toeject drops of material towards the support member, an actuatoroperatively connected to the at least one printhead, and a controlleroperatively connected to the at least one printhead and the actuator.The controller is configured to operate the actuator to move the atleast one printhead over the support member and to operate the printheadto eject drops of material towards the support member to enable the atleast one printhead to form the three-dimensional object about thecomponent held by the at least one positioning member and to enable thethree-dimensional object and the component to be released from the atleast one positioning member after the three-dimensional object isformed about the component.

A manufacturing method that uses a device to facilitate the manufactureof three-dimensionally printed objects having precisely positionedcomponents includes mounting at least one positioning member on asupport member, mounting components within the positioning members tohold the component at a predetermined position with reference to thesupport member, operating with a controller at least one printhead toeject drops of material to form object structure about the positionedcomponents while the controller operates an actuator to move the atleast one printhead with reference to the support member, operating acuring device with the controller to cure the object structure, andremoving the component positioning device from the object structure.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and other features of the present disclosure areexplained in the following description, taken in connection with theaccompanying drawings.

FIG. 1 is an embodiment of a device that facilitates manufacture of anobject incorporating precisely positioned components.

FIG. 2 depicts two optical lenses precisely positioned by the device ofFIG. 1.

FIG. 3 depicts a printed structure of an object that incorporates theprecisely positioned lenses of FIG. 2.

FIG. 4 depicts the printed structure of the object that incorporates theprecisely positioned lenses freed from the device shown in FIGS. 1, 2,and 3.

FIG. 5 is a flow diagram of a process for operating a printer with adevice that facilitates the manufacture of an object incorporatingprecisely positioned components.

DETAILED DESCRIPTION

For a general understanding of the present embodiments, reference ismade to the drawings. In the drawings, like reference numerals have beenused throughout to designate like elements.

FIG. 1 depicts a component positioning device that enables repetitivemanufacture of three-dimensionally printed objects having preciselypositioned parts with a three-dimensional object printer. The componentpositioning device 100 includes a support member 104, which isconfigured to support a three-dimensional object to be formed by athree-dimensional object printer, and at least one positioning member,which is mounted to the support member 104. As shown in the figure, thesupport member 104 is a planar structure, but in other embodiments ofthe device 100, the support member can be cylindrical, circular, orirregularly shaped. The embodiment shown in FIG. 1 to FIG. 4 has twopositioning members 108A and 108B, although other embodiments can havefewer or more positioning members. The positioning members 108A and 108Bare configured to hold a component at a predetermined position withreference to the support member to enable the three-dimensional objectprinter to form the three-dimensional object about the components heldby the positioning members.

The first positioning member 108A is mounted to the support member 104and the second positioning member 108B is mounted to the support member104. The first positioning member 108A is configured to hold a firstcomponent at a first predetermined position with reference to thesupport member 104 and the second positioning member 108B is configuredto hold a second component at a second predetermined position withreference to the support member 104. The first positioning member 108Ahas three protuberances 112 that are arranged in a triangularconfiguration to enable two of the protuberances 112 to supportdifferent sides of a component 116A as shown in FIG. 2, while the thirdprotuberance 112 holds the component against the first twoprotuberances. Similarly, the second positioning member 108B has threeprotuberances 112 that are arranged in a triangular configuration toenable two of the protuberances 112 to support different sides of acomponent 116B as shown in FIG. 2, while the third protuberance 112holds the component 116B against the first two protuberances. Otherconfigurations of protuberances or indentations can be used to formpositioning members. As used in this document, positioning member refersto any structure configured to hold a previously fabricated component ata particular position, orientation, or location so a three-dimensionalobject can be printed to incorporate the previously fabricated componentwithin the object. One or more positioning members can be configured toconstrain a previously fabricated component in one, two, or threedimensions while an object is printed about the component.

The support member 104 and the positioning members 108A and 108B arewithin a three-dimensional object printer having at least one printhead140, an actuator 144, a curing device 152, and a controller 148. Thecontroller 148 is operatively connected to the at least one printhead140, the actuator 144, and the curing device 152 and is configured tooperate these devices. Specifically, the controller 148 is configuredwith programmed instructions stored in a memory operatively connected tothe controller that cause the controller 148 to operate these deviceswhen the instructions are executed. The controller operates the actuator144 to move the at least one printhead 140 and the curing device 152with reference to the surface of the support member 104. The controller148 operates the at least one printhead 140 as it operates the actuator144 to move the at least one printhead 140 to eject drops of materialtowards the support member 104 to form object structure and objectsupport structure. The controller 148 operates the curing device 152 asit operates the actuator 144 to move the curing device 152 to cureobject structure. The curing device 152 can be a radiator of ultraviolet(UV) radiation or some other wavelength of electromagnetic radiation.

In FIG. 2, the components 116A and 116B are optical lenses that are heldat a focal length from one another by the first positioning member 108Aand the second positioning member 108B. Other types of components thatrequire precise positioning with reference to one another can be usedwith another embodiment of device 100. Such components include otheroptical components used to shape laser beams or micro electromechanicalsystem components used to form accelerometers or other sensinginstruments. Installing the components 116A and 116B within thepositioning members 108A and 108B enables the printing of athree-dimensional object about the components, rather than requiring thepositioning features of the object to be formed first and then thecomponents installed within the object as part of its manufacture.

As shown in FIG. 3, the controller 148 operates inkjets within the atleast one printhead 140 to form a base structure 120 and supportingstructures 124 that secure the two components 116A and 116B at the twoprecisely positioned locations determined by positioning members 108Aand 108B. The controller 148 can operate the at least one printhead 140to eject materials having different coefficients of thermal expansion.Such materials help maintain the spatial relationships between thecomponents as the object is heated and cooled. From time to time, thecontroller 148 operates the curing device 152 as it operates theactuator 144 to move the curing device over the support member 104 tocure the drops of ejected material. In FIG. 4, the device 100 has beenremoved after the printed structure has been cured. To enable removal ofthe device 100, the printer is operated to form the structure 120 withopenings about the protuberances 112 so the protuberances of the device100 do not adhere to or are entangled with printed structures 120 and124. Once the device 100 is removed from the object having basestructure 120, the device is available for installing another set ofcomponents for the formation of a new object incorporating preciselypositioned components as determined by the positioning members of thedevice 100. The reuse of the device 100 enables multiple objects to bemanufactured with precisely positioned components without the machiningof a part with high tolerances each time.

A process 500 for operating a printing system with a device 100configured as described above is shown in FIG. 5. Statements that theprocess is performing some task or function refers to a controller orgeneral purpose processor executing programmed instructions stored innon-transitory computer readable storage media operatively connected tothe controller or processor to manipulate data and operate one or morecomponents in the system to perform the task or function. The controllerof the printing system can be configured with components and programmedinstructions to provide a controller or processor that performs theprocess 500. Alternatively, the controller can be implemented with morethan one processor and associated circuitry and components, each ofwhich is configured to form one or more tasks or functions describedbelow.

With reference to FIG. 5, the process 500 begins with mounting thepositioning members on the support member and the mounting of componentswithin the positioning members of the component positioning device 100(block 504). The controller of the printer operates one or moreprintheads of the printer to form object structure about the twoprecisely positioned components (block 508). This object structure caninclude structures made with different materials having differentcoefficients of thermal expansion. The different coefficients of thermalexpansion enable the components to maintain their original distancerelationships with one another as the object is heated and cooled.Standard machining or subtractive manufacturing methods do notaccommodate the use of different thermal expansion materials so easily.Additionally, the object structure can include the formation of mountingholes and members so the object formed by the process 500 can be easilyand quickly incorporated in another object or device. The positioningmembers also permit partial structures to be built about one or morecomponents, the positioning members removed, and the partial structurescompleted. The term “printheads” refers to any device capable of formingan object or support structure for forming an object with one or morematerials. Such devices include printheads, extruders, stereolithographysystems, and the like. The printed structure is cured (block 512) andthe device 100 is removed from the object (block 516). To enable removalof the device 100, the printer is operated to form the object structureabout the positioning members with openings that enable the positioningmembers not adhere to or become entangled with printed structure. Oncethe device is removed from the object, the device is available forinstalling another set of components for the formation of a new objectincorporating precisely positioned components as determined by thepositioning members of the device 100.

Those skilled in the art will recognize that numerous modifications canbe made to the specific implementations described above. Therefore, thefollowing claims are not to be limited to the specific embodimentsillustrated and described above. The claims, as originally presented andas they may be amended, encompass variations, alternatives,modifications, improvements, equivalents, and substantial equivalents ofthe embodiments and teachings disclosed herein, including those that arepresently unforeseen or unappreciated, and that, for example, may arisefrom applicants/patentees and others.

1. A printer that enables repetitive manufacture of three-dimensionallyprinted objects having precisely positioned parts comprising: a supportmember configured to support a three-dimensional object to be formed bya three-dimensional object printer; at least one positioning membermounted to the support member, the at least one positioning member beingconfigured to hold a component at a predetermined position withreference to the support member; at least one printhead configured toeject drops of material towards the support member; an actuatoroperatively connected to the at least one printhead; and a controlleroperatively connected to the at least one printhead and the actuator,the controller being configured to operate the actuator to move the atleast one printhead over the support member and to operate the printheadto eject drops of material towards the support member to enable the atleast one printhead to form the three-dimensional object about thecomponent held by the at least one positioning member and to enable thethree-dimensional object and the component to be released from the atleast one positioning member after the three-dimensional object isformed about the component.
 2. The printer of claim 1, the at least onepositioning member further comprising: a plurality of protuberances thatextend above a surface of the support member.
 3. The printer of claim 2wherein the plurality of protuberances that extend above the surface ofthe support member are arranged in a triangular configuration.
 4. Theprinter of claim 1, the at least one positioning member furthercomprising: a first positioning member mounted to the support member,the first positioning member being configured to hold a first componentat a first predetermined position with reference to the support member;and a second positioning member mounted to the support member, thesecond positioning member being configured to hold a second component ata second predetermined position with reference to the support member toenable the controller to operate the actuator and the at least oneprinthead to form the three-dimensional object about the first componentheld by the first positioning member and the second component held bythe second positioning member and to enable the three-dimensional objectand the first and second components to be released from the firstpositioning member and the second positioning member after thethree-dimensional object is formed about the first component and thesecond component.
 5. The printer of claim 4 wherein the firstpredetermined position of the first component and the secondpredetermined position of the second component correspond to a focallength between two optical lenses.
 6. The printer of claim 4, the firstpositioning member further comprising: a first plurality ofprotuberances that extend above a surface of the support member; and thesecond positioning member further comprising: a second plurality ofprotuberances that extend above the support member.
 7. The printer ofclaim 6 wherein the first plurality of protuberances are arranged in afirst triangular configuration and the second plurality of protuberancesare arranged in a second triangular configuration.
 8. The printer ofclaim 4, the at least one printhead being configured to eject drops ofdifferent materials having different coefficients of thermal expansion;and the controller being further configured to operate the at least oneprinthead to eject drops of a material having a first coefficient ofthermal expansion to form structure about the first component and tooperate the at least one printhead to eject drops of another materialhaving a second coefficient of thermal expansion to form structure aboutthe second component, the first coefficient of thermal expansion beingdifferent than the second coefficient of thermal expansion.
 9. Theprinter of claim 1, the controller being further configured to operatethe at least one printhead to eject drops of material to form mountingstructure about the component to enable the object formed about thecomponent to be installed in another object.
 10. A method for operatinga printer to form a three-dimensional object with precisely positionedcomponents comprising: mounting at least one positioning member on asupport member; mounting components within the positioning members tohold the component at a predetermined position with reference to thesupport member; operating with a controller at least one printhead toeject drops of material to form object structure about the positionedcomponents while the controller operates an actuator to move the atleast one printhead with reference to the support member; operating acuring device with the controller to cure the object structure; andremoving the component positioning device from the object structure. 11.The method of claim 10, the mounting of the at least one positioningmember on the support member further comprising: orienting the at leastone positioning member to enable a plurality of protuberances to extendabove a surface of the support member.
 12. The method of claim 10wherein the at least one positioning member has a plurality ofprotuberances arranged in a triangular configuration.
 13. The method ofclaim 10, the mounting of the at least one positioning member to thesupport member further comprising: mounting a first positioning memberto the support member, the first positioning member being configured tohold a first component at a first predetermined position with referenceto the support member; and mounting a second positioning member to thesupport member, the second positioning member being configured to hold asecond component at a second predetermined position with reference tothe support member to enable the controller to operate the actuator andthe at least one printhead to form the three-dimensional object aboutthe first component held by the first positioning member and the secondcomponent held by the second positioning member and to enable thethree-dimensional object and the first and second components to bereleased from the first positioning member and the second positioningmember after the three-dimensional object is formed about the firstcomponent and the second component.
 14. The method of claim 13, themounting of the first positioning member and the mounting of the secondpositioning member further comprise: mounting the first and the secondpositioning members to position the first component and the secondcomponent at a distance from one another that corresponds to a focallength between two optical lenses.
 15. The method of claim 13, themounting of the first positioning member and the second positioningmember further comprising: orienting the first positioning member toenable a first plurality of protuberances to extend above a surface ofthe support member; and orienting the second positioning member toenable a second plurality of protuberances to extend above the surfaceof the support member.
 16. The method of claim 15 wherein the firstplurality of protuberances of the first positioning member are arrangedin a first triangular configuration and the second plurality ofprotuberances of the second positioning member are arranged in a secondtriangular configuration.
 17. The method of claim 13 further comprising:operating the at least one printhead to eject drops of a material havinga first coefficient of thermal expansion to form structure about thefirst component; and operating the at least one printhead to eject dropsof another material having a second coefficient of thermal expansion toform structure about the second component, the first coefficient ofthermal expansion being different than the second coefficient of thermalexpansion.
 18. The method of claim 10 further comprising: operating theat least one printhead to eject drops of material to form mountingstructure about the component to enable the object formed about thecomponent to be installed in another object.